CN109877295B - Manufacturing method of aluminum-ceramic composite brake disc - Google Patents
Manufacturing method of aluminum-ceramic composite brake disc Download PDFInfo
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Abstract
The invention discloses a manufacturing method of an aluminum-ceramic composite brake disc, relates to the field of manufacturing of vehicle brake discs, and particularly relates to a manufacturing method of an aluminum-ceramic composite brake disc. The invention provides a lightweight structure of an aluminum-ceramic brake disc, which ensures the structural rigidity and the wear resistance and has a low cost. The method mainly comprises the following steps: firstly, performing melt-state heat seal on a disk core; secondly, smelting and casting an aluminum alloy disc body; thirdly, annealing; fourthly, heat treatment of the brake disc; and fifthly, machining. The invention adopts foamed ceramics with porosity or foamed ceramics and aluminum alloy to manufacture by solid-liquid compounding, the ceramic disk core adopts a molten state heat seal technology to realize effective connection, and the continuous interface of the ceramic and aluminum interface is realized after aluminum liquid is infiltrated into the ceramic. The invention can ensure the integral structural rigidity of the brake disc and can realize light weight design, the disc body is connected with the wheel spindle through the screw rod, the braking effect is increased, and the method has simple preparation process and low cost.
Description
Technical Field
The invention relates to the field of manufacturing of vehicle brake discs, in particular to a manufacturing method of a composite brake disc.
Background
In the field of traffic manufacturing, although electric braking has been developed to be extremely mature, the effect of mechanical braking still occupies an important position, and when the electric braking fails, effective braking effect must be exerted to ensure the safety of personnel and vehicles. At present, the composite brake disc has excellent comprehensive performance and lighter material, and is easy to realize lightweight manufacturing.
The invention patent (2018113412493) discloses a method for casting an aluminum-steel composite brake disc by solid-liquid composite extrusion, the composite brake disc comprises a disc core made of steel and a disc body cast by aluminum alloy, and is prepared by the solid-liquid composite extrusion casting method, and the brake disc has excellent wear resistance and obvious light weight effect. However, the steel-aluminum interface bonding in the method belongs to mechanical bonding, the bonding strength is weak, the risk of cracking of the bonding surfaces of the steel and the aluminum is possibly existed in the use process, and meanwhile, the weight reduction effect is limited because the material of the disc core is still steel.
The invention patent (CN108331863A) discloses a hybrid light brake disc and a manufacturing method thereof. The hybrid lightweight brake disc has a brake chamber and a friction ring with at least one circular outer friction surface. The brake chamber is composed of a material of an aluminum wrought alloy, and a friction ring composed of a rapidly solidified aluminum alloy is built on an edge region of the brake chamber by using a laser deposition welding process or a 3D printing process. The invention can effectively reduce the whole weight of the brake disc and realize the purpose of light weight, but the preparation process of the method is complex, and the full aluminum alloy material can not ensure enough wear resistance.
The invention patent (CN107100949A) provides a combined composite material brake disc, a preparation method and application, the method provides a method for using a gradient composite material and a carbon ceramic matrix composite material as a brake disc after being mutually matched, although the brake disc structure and the material of the method are advanced and the lightweight effect is obvious, the brake disc prepared by the method has complex preparation process and high preparation cost, and industrial production is difficult to realize.
Therefore, the primary objectives of lightweight brake disc manufacturing at present are to realize lightweight brake disc structures, ensure comprehensive performances such as structural rigidity and wear resistance, and realize low-cost industrial manufacturing.
Disclosure of Invention
The invention aims to realize the lightweight design of a brake disc, ensure the structural rigidity and the sufficient wear resistance of the brake disc, realize the preparation by adopting a simple process flow and realize the industrial production, and further provide a manufacturing method of the aluminum-ceramic composite brake disc.
The invention relates to a manufacturing method of an aluminum-ceramic composite brake disc, which comprises the following steps:
firstly, prefabricating a ceramic framework disc core: manufacturing a ceramic framework with pores as blanks of a left disc, a right disc and a connecting column according to actual requirements of friction surfaces of a left brake disc and a right brake disc, combining the left disc, the right disc and the connecting column into a disc core by adopting molten heat seal, and cooling to obtain a disc core group;
secondly, smelting and casting an aluminum alloy plate blank: smelting aluminum alloy by using a smelting furnace to obtain molten aluminum liquid; putting the disc core assembly obtained in the step one into an extrusion casting mold, injecting molten aluminum into the extrusion casting mold, applying pressure and maintaining pressure through a pressurizing device, completing infiltration of the molten aluminum into the disc core assembly, and cooling, solidifying and molding;
thirdly, heat treatment of the brake disc blank: carrying out corresponding graded heating according to the type of the smelted aluminum alloy, and carrying out T6 heat treatment process when the temperature is raised to the solid solution temperature of the aluminum alloy in a graded manner to obtain a brake disc blank;
fourthly, machining: and (4) carrying out mechanical processing of driving, drilling, thread machining and grinding on the brake disc blank obtained in the third step, and obtaining the aluminum-ceramic composite brake disc after the processing is finished.
The invention has the beneficial effects that:
the brake disc adopts an aluminum-ceramic composite structure, the brake disc is prepared by compounding ceramic and molten aluminum alloy, and the composite structure ensures the requirement of the brake disc on the wear resistance and ensures the braking effect. The aluminum-ceramic composite structure is adopted, wherein the ceramic is foamed ceramic or foamed ceramic with certain porosity, and traditional materials such as cast iron and the like are not adopted, so that the overall weight of the brake disc is effectively reduced, and the aluminum-ceramic composite structure has an excellent light weight effect.
The invention adopts the technique of melt heat seal to manufacture the ceramic disk core, thereby ensuring the connection strength of the disk core parts and effectively reducing the manufacturing cost.
The invention adopts an aluminum-ceramic liquid-solid extrusion casting composite method, the aluminum alloy is extruded into the ceramic gap in a liquid state, the aluminum alloy is in a continuous state, no obvious interface exists between the ceramic and the aluminum alloy, and the bonding strength and the density of the aluminum alloy matrix and the ceramic disk core are effectively ensured.
The heat treatment process adopted in the invention is a graded heating T6 heat treatment process, which ensures that the component is not damaged due to internal stress and can effectively ensure the T6 heat treatment effect.
Drawings
FIG. 1 is a schematic structural view of an aluminum-steel composite brake disc;
fig. 2 is a partial schematic view of the left disc.
Detailed Description
The technical solution of the present invention is not limited to the following specific embodiments, but includes any combination of the specific embodiments.
The first embodiment is as follows: the manufacturing method of the aluminum-ceramic composite brake disc of the embodiment is carried out according to the following steps:
firstly, prefabricating a ceramic framework disc core: according to the actual requirements of the friction surfaces of the left brake disc and the right brake disc, manufacturing a ceramic framework with pores as blanks of the left disc 3, the right disc 4 and the connecting column 5, combining the left disc 3, the right disc 4 and the connecting column 5 into a disc core by adopting molten heat seal, and cooling to obtain a disc core group;
secondly, smelting and casting an aluminum alloy plate blank: smelting aluminum alloy by using a smelting furnace to obtain molten aluminum liquid; putting the disc core assembly obtained in the step one into an extrusion casting mold, injecting molten aluminum into the extrusion casting mold, applying pressure and maintaining pressure through a pressurizing device, completing infiltration of the molten aluminum into the disc core assembly, and cooling, solidifying and molding;
thirdly, heat treatment of the brake disc blank: carrying out corresponding graded heating according to the type of the smelted aluminum alloy, and carrying out T6 heat treatment process when the temperature is raised to the solid solution temperature of the aluminum alloy in a graded manner to obtain a brake disc blank;
fourthly, machining: and (4) carrying out mechanical processing of driving, drilling, thread machining and grinding on the brake disc blank obtained in the third step, and obtaining the aluminum-ceramic composite brake disc after the processing is finished.
The second embodiment is as follows: the first difference between the present embodiment and the specific embodiment is: the aluminum-ceramic composite brake disc consists of a disc core 1 and a disc body 2; the disc core 1 consists of a left disc 3, a right disc 4 and a connecting column 5; the left disc 3, the right disc 4 and the connecting column 5 are all made of ceramics, symmetrical through holes are formed in the centers of the left disc 3 and the right disc 4, the left disc 3 and the right disc 4 are placed in a left-right centering mode, and a plurality of cylindrical pits 6 are uniformly distributed on the opposite inner sides of the left disc 3 and the right disc 4; the left disc 3 and the right disc 4 are connected through uniformly distributed connecting columns 5 in a fusion state in a heat sealing manner; disk body 2 is formed by aluminum alloy extrusion casting, the left side of disk body 2 is provided with the boss of wearing out left side dish 3, the boss distributes a plurality of screw holes 7 along the surface of axle center through machining. The rest is the same as the first embodiment.
The third concrete implementation mode: the present embodiment differs from the first or second embodiment in that: in the step one, the ceramic with pores is foamed ceramic or foamed ceramic; the porosity of the ceramic with pores is 5-50%. The others are the same as in the first or second embodiment.
The fourth concrete implementation mode: the difference between this embodiment mode and one of the first to third embodiment modes is: in the step one, the molten state heat seal is to heat the surface of the porous ceramic framework to the melting point, and then hot press the ceramic framework for 1-2 hours under the conditions that the pressure is 10-20 kN and the temperature is 1500-1800 ℃. The rest is the same as one of the first to third embodiments.
The fifth concrete implementation mode: the difference between this embodiment and one of the first to fourth embodiments is: and the smelting temperature in the second step is 700-850 ℃. The rest is the same as one of the first to fourth embodiments.
The sixth specific implementation mode: the difference between this embodiment and one of the first to fifth embodiments is: before injecting molten aluminum into an extrusion casting mold, putting the disc core assembly into the extrusion casting mold with the temperature of 550-610 ℃ for heat preservation; and ensuring that the heat preservation time and the aluminum alloy smelting time arrive at the same time. The rest is the same as one of the first to fifth embodiments.
The seventh embodiment: the difference between this embodiment and one of the first to sixth embodiments is: the step three is that the temperature rise process is divided into two stages, the temperature is raised to 60-70% of the solid solution temperature of the selected aluminum alloy in the first stage, and the temperature is kept for 20-30 min; and in the second stage, raising the temperature to the solid solution temperature of the aluminum alloy, and keeping the temperature for 1-2 hours. The rest is the same as one of the first to sixth embodiments.
The specific implementation mode is eight: the present embodiment differs from one of the first to seventh embodiments in that: the aluminum alloys in step three are 2XXX, 6XXX, and 7XXX series aluminum alloys. The rest is the same as one of the first to seventh embodiments.
The following examples were used to demonstrate the beneficial effects of the present invention:
example (b): the manufacturing method of the aluminum-ceramic composite brake disc comprises the following steps:
firstly, fusion heat sealing of a disk core: preparing a left disk core, a right disk core and a connecting column of a foamed ceramic with the porosity of 20% according to design requirements, placing a small amount of ceramic powder at the joint of the disk core and the connecting column, combining the left disk core, the right disk core and the connecting column according to the disk core, and applying a pressure of 15 KN. The device is placed in a high-temperature furnace, heated to 1800 ℃, kept for 1.5h, and cooled in the furnace to obtain the disc core.
Secondly, smelting and casting an aluminum alloy plate body: and (3) smelting the 2024 aluminum alloy by using a smelting furnace, controlling the smelting temperature to be 810 ℃, smelting for 40min, putting the ceramic disc core obtained in the step two into an extrusion casting die, injecting the molten 2024 aluminum liquid into the die, applying 100KN pressure through a pressurizing device, maintaining the pressure for 30min, cooling, solidifying and forming to obtain the brake disc rough blank.
Thirdly, brake disc heat treatment: heating the brake disc in a furnace to 495 ℃, preserving heat for 1h, then carrying out water quenching, and then carrying out artificial aging treatment at 160 ℃, wherein the treatment time is 8 h;
fourthly, machining: and C, carrying out corresponding machining processes of turning, drilling, machining threads and grinding on the brake disc obtained in the fourth step, and obtaining the aluminum-ceramic composite brake disc after machining is finished.
The table below shows the weight reduction effect of the aluminum-ceramic composite brake disc in the example and the aluminum-steel composite brake disc in the invention patent (2018113412493), and the interface bonding mode and performance comparison results.
Claims (3)
1. A manufacturing method of an aluminum-ceramic composite brake disc is characterized in that the manufacturing method of the aluminum-ceramic composite brake disc is carried out according to the following steps:
firstly, prefabricating a ceramic framework disc core: according to the actual requirements of friction surfaces of a left brake disc and a right brake disc, manufacturing a ceramic framework with pores as blanks of the left disc (3), the right disc (4) and a connecting column (5), combining the left disc (3), the right disc (4) and the connecting column (5) into a disc core by adopting molten state heat seal, and cooling to obtain a disc core group; the ceramic with pores is foamed ceramic or foamed ceramic; the porosity of the ceramic with pores is 5 to 50 percent; the molten heat seal is to heat the surface of the porous ceramic skeleton to the melting point, and then hot press the ceramic skeleton for 1 to 2 hours under the conditions that the pressure is 10 to 20kN and the temperature is 1500 to 1800 ℃; a plurality of cylindrical pits (6) are distributed on the opposite inner sides of the left disc (3) and the right disc (4);
secondly, smelting and casting an aluminum alloy plate blank: smelting aluminum alloy by using a smelting furnace to obtain molten aluminum liquid; putting the disc core assembly obtained in the step one into an extrusion casting mold, injecting molten aluminum into the extrusion casting mold, applying pressure and maintaining pressure through a pressurizing device, completing infiltration of the molten aluminum into the disc core assembly, and cooling, solidifying and molding; the smelting temperature is 700-850 ℃; before injecting molten aluminum into an extrusion casting mold, putting the disc core assembly into the extrusion casting mold with the temperature of 550-610 ℃ for heat preservation; ensuring that the heat preservation time and the aluminum alloy smelting time reach at the same time;
thirdly, heat treatment of the brake disc blank: carrying out corresponding graded heating according to the type of the smelted aluminum alloy, and carrying out T6 heat treatment process when the temperature is raised to the solid solution temperature of the aluminum alloy in a graded manner to obtain a brake disc blank; the step heating is that the heating process is divided into two stages, wherein in the first stage, the temperature is raised to 60-70% of the solid solution temperature of the selected aluminum alloy, and the temperature is kept for 20-30 min; in the second stage, heating to the solid solution temperature of the aluminum alloy, and keeping the temperature for 1-2 hours;
fourthly, machining: and (4) carrying out mechanical processing of driving, drilling, thread machining and grinding on the brake disc blank obtained in the third step, and obtaining the aluminum-ceramic composite brake disc after the processing is finished.
2. A manufacturing method of an aluminum-ceramic composite brake disc according to claim 1, characterized in that the aluminum-ceramic composite brake disc is composed of a disc core (1) and a disc body (2); the disc core (1) consists of a left disc (3), a right disc (4) and a connecting column (5); the left disc (3), the right disc (4) and the connecting column (5) are made of ceramics, symmetrical through holes are formed in the centers of the left disc (3) and the right disc (4), the left disc (3) and the right disc (4) are placed in a left-right centering mode, and a plurality of cylindrical pits (6) are uniformly distributed on the opposite inner sides of the left disc (3) and the right disc (4); the left disc (3) and the right disc (4) are connected through uniformly distributed connecting columns (5) in a fusion state in a heat sealing manner; disk body (2) are formed by aluminum alloy extrusion casting, the left side of disk body (2) is provided with the boss of wearing out left side dish (3), a plurality of screw holes (7) are distributed through machining along the surface in the axle center to the boss.
3. The method of claim 1, wherein in step three the aluminum alloys are 2XXX, 6XXX and 7XXX series aluminum alloys.
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| CN113523240A (en) * | 2021-07-19 | 2021-10-22 | 青岛力晨新材料科技有限公司 | Bimetal composite board and preparation method thereof |
| CN113404724B (en) * | 2021-07-30 | 2022-11-25 | 汉江弘源襄阳碳化硅特种陶瓷有限责任公司 | Metal composite silicon carbide ceramic impeller and manufacturing method thereof |
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| CN105041921A (en) * | 2015-07-09 | 2015-11-11 | 余姚市海博机械有限公司 | Automobile brake disc and manufacturing method thereof |
| CN107876730A (en) * | 2017-11-13 | 2018-04-06 | 宁波海瑞时新材料有限公司 | The light metal-based composite of high-abrasive material, local enhancement and preparation method |
| KR20180053818A (en) * | 2016-11-14 | 2018-05-24 | 주식회사 세명테크 | Integrated hub and hybrid brake device including the same |
| CN109128079A (en) * | 2018-11-12 | 2019-01-04 | 福建祥鑫股份有限公司 | A kind of solid-liquid Compound Extrusion casting aluminium-steel composite brake disc method |
| CN109210110A (en) * | 2017-06-30 | 2019-01-15 | 本田技研工业株式会社 | High-performance brake disc rotor |
| CN109210111A (en) * | 2017-07-06 | 2019-01-15 | 通用汽车环球科技运作有限责任公司 | brake disc with decorative insert |
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2019
- 2019-04-24 CN CN201910335223.6A patent/CN109877295B/en active Active
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105041921A (en) * | 2015-07-09 | 2015-11-11 | 余姚市海博机械有限公司 | Automobile brake disc and manufacturing method thereof |
| KR20180053818A (en) * | 2016-11-14 | 2018-05-24 | 주식회사 세명테크 | Integrated hub and hybrid brake device including the same |
| CN109210110A (en) * | 2017-06-30 | 2019-01-15 | 本田技研工业株式会社 | High-performance brake disc rotor |
| CN109210111A (en) * | 2017-07-06 | 2019-01-15 | 通用汽车环球科技运作有限责任公司 | brake disc with decorative insert |
| CN107876730A (en) * | 2017-11-13 | 2018-04-06 | 宁波海瑞时新材料有限公司 | The light metal-based composite of high-abrasive material, local enhancement and preparation method |
| CN109128079A (en) * | 2018-11-12 | 2019-01-04 | 福建祥鑫股份有限公司 | A kind of solid-liquid Compound Extrusion casting aluminium-steel composite brake disc method |
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Denomination of invention: A manufacturing method of aluminum ceramic composite brake disc Effective date of registration: 20210916 Granted publication date: 20200915 Pledgee: China Exim Bank Fujian branch Pledgor: FUJIAN XIANGXIN SHARES Co.,Ltd. Registration number: Y2021350000112 |
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Denomination of invention: A manufacturing method of aluminum ceramic composite brake disc Effective date of registration: 20220923 Granted publication date: 20200915 Pledgee: China Exim Bank Fujian branch Pledgor: FUJIAN XIANGXIN SHARES Co.,Ltd. Registration number: Y2022350000122 |
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